Turbo Technologies

NUMBER REVISION
DOCUMENT TITLE PAGE AND REVISION RECORD IDM-4214 N
DOCUMENT TYPE PAGE 1 OF 8
MATERIALS SPECIFICATION
TITLE
SAND CAST ALUMINUM ALLOY – 356-T6
PREPARED BY APPROVED APPROVED

E. H. Schmidt R. Cholvin
LAST REVISED BY APPROVED APPROVED

Klara Hanzlikova N/A N/A

PROPRIETARY NOTICE
This Document contains proprietary information and such information may not be disclosed to others for any purpose or used for manufacturing
without written permission from Honeywell, Inc.

REVISION RECORD
REV. ITEM
LTR. ECN NO. DATE DESCRIPTION CHECKED APPROVED

H 48894 Pg.2 03/28/89 Section 4.1, Mg Lower Limit was .20 KR LSC

J 54951 Pg.4 05/21/93 Added Section 8.0 RJG

K 62994A 03/04/98 Converted to MSWord BC BB

L 68245 1 12/12/00 Updated Section 7.0 according to recent BC BB

Standards

2 Completely revised according to last template

Updated onto new IDM template
M ECN-09-00920 1 DC KH
Added IMDS/Reach compliance statement
2
Added Section 7.3 & 8
3

4 Revised Section 9 in its entirety

Section 11: Standardized list of equivalent
5 materials
Section 6.1.1: Changed Lead Max from 0.15 to
N ECN-10-02004 1 02/16/11 0.05 DC CK
Section 11.1: Added sentence “However, the
2 lead…specified in 6.1.1.”

DISTRIBUTION: per CDI-0004

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1. Introduction

1.1. This specification applies to aluminum alloy 356, which has to be cast in sand moulds. This
material exhibits high mechanical properties, especially after heat treatment. This material is
intended to be used for making backplates, compressor housing, valve bodies, etc.

1.2. This specification does not constitute a grant of license, sublicense or any actual or implied right to
use any patent or other intellectual property right of a third party which may be infringed by
compositions, materials or components (collectively Supplied Goods), or processes employed for
preparation, manufacture or fabrication of Supplied Goods, meeting the requirements defined
herein. Suppliers further warrant that Supplied Goods do not infringe any patent or other
intellectual property right of a third party.

1.3. Upon request, in a form and substance satisfactory to enable Honeywell to meet its compliance
obligations with regards to Regulation (EC) No. 1907/2006 (“REACH”), ELV Directive No. 2000-
53-EC and associated annexes, or similar laws or regulations identified by Honeywell, Vendors will
provide Honeywell with complete information regarding the chemical composition of any Goods
(substances, preparations, mixtures, alloys or goods) supplied under this Materials Specification,
including all safety information required under REACH and information regarding the registration
or pre-registration status of any Goods pursuant to REACH.

1.4. Vendors shall ensure that all information requested in paragraphs 7.1.1, and 7.2.1 are explicitly
stated for each part number on the drawing. The lack of this information shall be considered as
non-compliance and the drawing shall be updated. Vendors shall mention this specification and its
revision letter, and international material designation in all quotations and when acknowledging
purchase orders.

2. Scope

This specification describes the condition, chemical and technical requirements for aluminum alloy 356,
which has to be cast in sand moulds.

3. Definitions, Abbreviations and Symbols

ECHA European Chemicals Agency

ELV End of Life Vehicles Regulations
PI Process Instruction (a Honeywell Turbo Technologies Document)
QCI Quality Control Instruction (a Honeywell Turbo Technologies Document)
REACH Registration, Evaluation, Authorisation and restriction of Chemicals
SVHC Substances of Very High Concern

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4. List of Related Documents

PI-5780 Identification of Castings and Injection Moulded Plastic Parts

QCI-9310-175 Standards for Retesting of Properties of Materials
QCI-9310-239 Tensile Testing of Metallic Materials

5. Condition Requirements

5.1. Condition
5.1.1. This material shall be sand cast.
5.1.2. The material shall be supplied in the T6 condition.

6. Chemical Requirements

6.1. Chemical Composition

6.1.1. The chemical composition of material supplied to this specification shall conform to
the following:

Element Min (%) Max (%)

Copper -- 0.25
Iron -- 0.60
Magnesium 0.20 0.65
Manganese -- 0.6
Silicon 6.5 7.5
Titanium -- 0.25
Zinc -- 0.35
Nickel 0.15
Lead 0.05
Other Elements Tested (each) -- 0.05
Total Other Elements -- 0.15
Aluminum Balance

6.1.2. The other elements (OET) shall not contain the Candidate (SVHC) List substances
published by ECHA or shall not contain any restricted substances such as lead,
cadmium, mercury, hexavalent chromium as prescribed in ELV Directive No. 2000-53-
EC and associated annexes or other similar laws or regulations available for restricting
substances globally in any region as updated from time to time. In case OET contains
SVHC then the percentage present needs to be notified.

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6.2. Chemical Analysis

6.2.1. Material shall conform to the composition requirements of paragraph 6.1. Analysis shall
be made regularly only for the elements specifically mentioned. If, however, the presence
of other elements is suspected or indicated in the course of routine analysis, further
analysis shall be made to determine that the total of other elements is not in excess of the
limits specified.

6.2.2. Material shall be analyzed by either wet chemical or spectrochemical methods and the type
of analysis reported. Measurement error for each element shall also be stated in the report.
In the event of a dispute between supplier and Honeywell Turbo Technologies, referee
analysis by a third party shall be by wet chemical analysis with standards traceable to the
National Bureau of Standards.
6.3. Use of Revert
The supplier may combine 356 alloy gates, sprues, risers, and scrap castings with virgin material
in any proportion in the preparation of master heats provided that control of chemical
composition and microstructure is adequate to ensure that the requirements of paragraph 6.1 are
met. They shall not be re-melted directly without refining for the pouring of castings.

7. Technical Requirements

7.1. Mechanical Properties

7.1.1. For Compressor housings, backplates and other parts involved in burst containment, the
mechanical properties shall be measured on a test bar machined from the casting as
indicated on the part drawing. The test bar shall conform to the dimensions shown in
Figure 1. Testing shall be done at room temperature at a strain rate of 0.005in/in min. and
shall yield the following minimum properties:

Property MPa ksi

0.2% Yield Strength 138 20
Ultimate Tensile Strength 207 30
Percent Elongation 3%
Note: If neck has insufficient stock for test bar, test as in Paragraph 7.1.2

7.1.2. For castings not involved in burst and containment, the mechanical properties shall be
measured using standard 5 inch diameter x2 inch gage length cast-to-size test bars poured
in green sand molds and heat treated with the castings they are intended to represent.
Testing shall be done at room temperature at a strain rate of 0.005 in/in. min and shall
yield the following minimum properties.

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Property MPa ksi

0.2% Yield Strength 138 20
Ultimate Tensile Strength 207 30
Percent Elongation 3%

7.2. Hardness
7.2.1. The location shall be as agreed upon by the supplier and the purchaser and shall be
explicitly stated for each part number on the engineering drawing.

7.2.2. The hardness of the material, unless otherwise indicated on the engineering drawing, shall
be a minimum of 65HBW10/500.

7.3. Microstructure
7.3.1. The microstructure of the material typically consists of a primary -aluminum matrix plus
a second phase based on the silicon eutectic.

7.3.2. The sample for microstructure examination shall be prepared by standard metallographic
techniques and etched (if applicable).

8. Additional Materials Information

The density of the material is 2680 kg/m3.

9. Quality

9.1. Castings shall conform to the quality, certification and identification requirements issued by
Purchaser’s Quality Assurance function for the appropriate part number.

9.2. Castings shall be uniform in quality and condition, sound and free from foreign materials and
from internal and external defects detrimental to fabrication or to performance of parts. Castings
shall have smooth surfaces and shall be well cleaned.

9.3. Porosity
9.3.1. Castings that contain latent foundry defects, which have been accepted, may be rejected
after machining if the machining operation exposes porosity or other defects that affect the
performance of the finished part.

9.3.2. Radiographic and other quality standards shall be as agreed upon by vendor and
Honeywell Turbo Technologies.

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9.3.3. Castings shall be produced under radiographic control. This shall consist of radiographic
examination of castings until proper foundry technique, which will produce castings free
from harmful internal defects, has been established for each mould and of production
castings as necessary to ensure maintenance of satisfactory quality.
9.4. Casting Repair
9.4.1. Castings shall not be repaired by plugging, welding or other methods without written
approval from the Honeywell Turbo Technologies. Any weld repair shall conform to the
applicable weld repair specification.

9.4.2. Castings shall not be impregnated, chemically treated or coated unless authorized in
writing by Honeywell Turbo Technologies. If impregnation is approved the applicable
specification shall be used.
9.5. Retesting
If initial test results fail to meet requirements and material is re-tested, such re-tests must be
carried out per QCI-9310-175.
9.6. Identification
Specified castings shall be identified in accordance with the engineering drawing and in
accordance with PI-5780.

10. Reports

10.1. Unless otherwise specified, the supplier shall retain at their facility the results of tests that
determine conformance of the parts to the requirements of this specification. Evidence of such is
to be on file for examination for a period of five years from the date of shipment.

10.2. The reports shall show the chemical composition, mechanical properties, microstructure, material
specification number (IDM and international material designation) and revision letter, purchase
order number and quantity. Honeywell Turbo Technologies reserved the right to perform tests to
verify that the material meets the requirements and to reject non-conforming material.

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11. Equivalent Materials

11.1. The materials listed below are equivalent to the material described in this specification and may
be used interchangeably provided that the technical requirements of this specification are met.
However, the lead (Pb) content shall not exceed that specified in 6.1.1.

11.2. This table is not an exhaustive list of equivalent materials; other equivalent materials may be
used provided that the proposal is acceptable to a competent person within the Materials
Engineering Group and that the technical requirements of this specification are met. Such
alternatives shall be explicitly documented as per the requirements in paragraphs 1.4 and 10.2 of
this specification.

Standard Numeric Symbolic

Country
Designation Designation Designation
Europe EN 1706 EN AC-42000 AlSi7Mg

United States ASTM B108 356.0

Japan JIS H5202 AC4C

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IN. MM

G GAGE LENGTH 1.000 ± 0.003 25.00 ± 0.08

W WIDTH 0.250 ± 0.002 6.25 ± 0.05
T THICKNESS
R. RADIUS OF FILLET, MIN. .25 6
L OVER-ALL LENGTH, MIN. 4 100
A LENGTH OF REDUCED SECTION, MIN. 1.25 32
B LENGTH OF GRIP SECTION, MIN. 1.25 32
C WIDTH OF GRIP SECTION, APPROXIMATE .375 10

FIGURE 1.

Test Bar to be Cut from Casting Outlet Neck as Shown on Part Drawing

NOTES

Ends of reduced section shall not differ in width by more than .001 inch. There may be a gradual decrease in
width from the ends to the center, but the width at each end shall not be more than .003 inch larger than the
width at the center.

Thickness T must be as large as outlet neck wall thickness permits, but not greater than .250 inch.

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